1 — the Forward bearing of a main shaft 2 — the Main shaft 3 — the Leading gear wheel of the 3rd transfer 4 — the Nave of the sliding synchronizer coupling 5 — the Persistent ring 6 — the Sliding coupling 7 — the Blocking ring of the 4th transfer 8 — the Leading gear wheel of the 4th transfer 9 — the Blocking ring of the synchronizer of the reverse gear 10 — the Cone of the synchronizer of the reverse gear 11 — the Nave of the sliding coupling of the synchronizer of the 5th transfer 12 — the Back bearing of a main shaft 13 — Adjusting rings of the back bearing of a main shaft 14 — the Spring key 15 — the Sliding synchronizer coupling 16 — the Blocking ring of the synchronizer of the 5th transfer 17 — the Leading gear wheel of the 5th transfer 18 — the Lock ring 19 — Persistent half rings of a main shaft 20 — the Spring key 21 — the Blocking ring of the synchronizer of the reverse gear 22 — the Blocking ring of the synchronizer of the 1st transfer 23 — the Blocking ring of the synchronizer of the 2nd transfer 24 — Adjusting rings of the back bearing of a secondary shaft 25 — the Back bearing of a secondary shaft 26 — the Persistent washer 27 — the Persistent ring

1 — the Cap of the lock of a fork of switching of the 3rd and 4th transfers 2 — the Fork of switching of 3-4 transfers 3 — the Lock ring 4 — the Fork of inclusion of the 5th transfer 5 — the Lock ring 6 — the Lock ring 7 — the Rod of a fork of inclusion of the 5th transfer 8 — the Blocking ball 9 — the Returnable spring 10 — the Control plug of the 5th and back transfers (16 ё 22 Nanometers) 11 — the Lock spring 12 — the Arm of the 5th and back transfers 13 — Pruzhina of the level of the reverse gear 14 — the Sealing ring 15 — the Pin 16 — the Axis of the lever of reverse motion 17 — the Sealing ring 18 — the Pin 19 — the Rod of the choice of transfers 20 — the Ball 21 — the Device of inclusion of a backing 22 — the Plunger of mutual blocking 23 — the Ball of mutual blocking 25 — the Ball 26 — the Returnable spring 27 — the Lock ring 28 — the Rod of a fork of switching of 3-4 transfers 29 — the Ball 30 — the Plunger of mutual blocking

Authors of the present manual do not recommend to owners of cars to undertake performance of capital repairs of RKPP independently. During performing procedures of dismantling and assembly of the transmission it is necessary to remove, and then to install into place a set of small components. It is necessary to perform a lot of the most exact measurements and, by selection of adjusting washers, rings and remote plugs, accurately to expose a set of gaps. In view of all aforesaid, performance of capital repairs of RKPP will be more reasonable to be charged to specialists of car service. Let's notice that in many cases there is an opportunity on an exchange basis to buy the restored block that is often cheaper, than carrying out complex repair.

Despite the told, independent performance of repair of RKPP by the amateur mechanic is not absolutely impossible action at all. Indispensable conditions are only existence of the necessary special tool and accuracy in approach to implementation of all procedures.

Nippers for removal of internal and external lock rings, a stripper of bearings, the hammer with sliding brisk, a set of drifts and center punches, the DTI measuring instrument and, perhaps, a hydraulic press are among tools, necessary for performance of recovery repair of RKPP. Besides, of course, the workbench, or the special assembly stand is required strong, equipped with a vice.

During performing procedures of dismantling of RKPP try to remember, and it is better to write down, an order of installation of each of the removed details.

Before starting dismantling of the transmission, it will be reasonable to try to analyse symptoms of its refusals for the purpose of approximate definition of their reasons. Many refusals are unambiguously connected with failure of quite certain components.

The schematic description of an order of procedures of dismantling of RKPP and service of its internal components is provided in the following subsection.

Dismantling, service of internal components and assembly of RKPP

Extraction of components

PERFORMANCE ORDER

1. The scheme of an arrangement of the RKPP internal components and the mechanism of the choice of transfers is submitted on illustrations.

2. Take a gear wheel of the 4th transfer through an opening, then remove an axis of an intermediate gear wheel of a backing and a gear wheel.

3. Take a fixing pin from the coupling case.

4. Remove a returnable spring of the lever and a lock spring of the reverse gear from the mechanism of turning on of the reverse gear.

5. Remove a pad of an axis of a gear wheel of the reverse gear.

6. Remove assembly of the lever of the reverse gear.

7. Remove a cap of the lock of a fork of inclusion of the 5th and back transfers, take a spring and a ball.

8. Remove lock rings and fixing pins from rods of forks of switching of 5/back and 3-4 transfers.

9. Remove rods of 5/back and 3-4 transfers.

10. Take assemblies of both shaft (primary and secondary) RKPP and a fork of 1-2 transfers with the rod.

11. Take assembly of the main transfer.

12. Remove assembly of the reverse gear.

13. By means of a special drift (KV32101000) take a fixing pin and disconnect the selector.

14. Turn out a drain stopper, for the purpose of ensuring access to a pin of fastening of the lever with a rod.

15. Take a pin (use KV32101000 drift) and remove the lever with a rod.

Dismantle of assembly of a main shaft

DISMANTLING

PERFORMANCE ORDER

1. Before starting dismantle of a main shaft, estimate the size of an axial side play of the leading gear wheels of the 3rd, 4th and 5th transfers.

2. If the side play of gear wheels exceeds the limit of admissible ranges (see Specifications), dismantle assembly and check a condition of the interfaced surfaces of gear wheels, a shaft and naves, then estimate a gap of a lock ring and persistent half rings of a main shaft.

3. Remove the back bearing of a main shaft.

4. Remove assemblies of synchronizers of the 5th and back transfers, and also the leading gear wheel of the 5th transfer.

5. Remove an axial lock washer, two persistent half rings and the leading gear wheel of the 4th transfer.

6. Remove a lock ring.

7. Remove the synchronizer of 3-4 transfers and the leading gear wheel of the 3rd transfer.

8. Remove the forward bearing of a main shaft.

Check of a condition of components

PERFORMANCE ORDER

1. Check assembly of a main shaft for existence of cracks, signs of deformations and excessive wear, estimate a condition of the leading gear wheels.

2. Check components of synchronizers for existence of cracks of signs of excessive wear, cracks and other mechanical defects. Estimate a condition of naves, the sliding couplings, the blocking rings, keys and other details of assemblies.

3. Measure gap size between the blocking ring of the synchronizer and a gear wheel (for the 4th and 5th transfers). The nominal rate lies within the range of 1.0 ÷ 1.35 mm with the admission on wear to 0.7 mm.

4. Estimate degree of wear of the blocking ring of the synchronizer of the reverse gear. Lay the blocking ring on suitable adaptation and place on it a synchronizer cone. Make sure that the projection of a cone gets to deepening perimeter in adaptation. With effort pressing a cone to the blocking ring, by means of the dial measuring instrument of plunger type define distance And. If size A makes less than 1.2 mm, replace the blocking ring.

6. Check bearing assemblies for existence of cracks, cavities and other mechanical damages.

ASSEMBLY

PERFORMANCE ORDER

1. Collect the synchronizer of 3-4 transfers. Track correctness of introduction of components to gearing.

2. Put the leading gear wheel of the 3rd transfer and the blocking ring of the corresponding synchronizer on assembly of a main shaft.

3. Press a nave of the coupling of the synchronizer of 3-4 transfers on assembly. Track for correctness of orientation of components. Pick up and establish the corresponding persistent ring, trying to obtain minimization of a gap in a groove (the size of a gap should not exceed the limit of the range of 0 ÷ 0.1 mm).

4. Put the leading gear wheel of the 4th transfer. 5. Pick up the corresponding persistent washers providing minimization of a gap in a groove (0 ÷ 0.06 mm) and put them on a persistent ring. 6. Install the synchronizer 5th and back transfers. Fill spring keys in the blocking ring of the synchronizer of the reverse gear. Enter assembly into the sliding synchronizer coupling, - track correctness of input in the coupling of spring keys.

7. Put the blocking ring of the 5th transfer to the corresponding leading gear wheel. Establish a cone of the synchronizer of the reverse gear on the blocking ring. Place the assembled synchronizer of a back preedacha on the leading gear wheel of the 5th transfer. Fill cone ledges in reciprocal grooves of a gear wheel.

1 — the Gear wheel of the 5th transfer 2 — Assembly of the synchronizer of the reverse gear

8. Place clamps spring rings of the blocking ring of the synchronizer of the reverse gear from above on the leading gear wheel of the 5th transfer.

9. Press assembly of the synchronizer of the 5th and back transfers with a gear wheel of the 5th transfer on assembly of a main shaft.

10. Put forward and back bearings on assembly of a main shaft.

11. Estimate the size of an axial side play of gear wheels.

Dismantle of assembly of a secondary shaft

DISMANTLING

PERFORMANCE ORDER

1. Before starting dismantle of components of assembly measure the size of an axial side play of the conducted gear wheels of the 1st and 2nd transfers. If results of measurements exceed the limit of admissible ranges (see Specifications), remove components and estimate a condition of the interfaced surfaces of a shaft, gear wheels and naves (see the subsection Assembly).

2. Vypressuyte back bearing of a secondary shaft.

3. Remove a persistent washer and a ring.

4. Vypressuyte the conducted gear wheels of the 5th and 4th transfers.

5. Vypressuyte the conducted gear wheels of the 3rd and 2nd transfers.

6. Remove a persistent ring.

7. Remove assembly of the synchronizer of 1-2 transfers and the conducted gear wheel of the 1st transfer.

8. Vypressuyte back bearing

Check of a condition of components

PERFORMANCE ORDER

1. Check a shaft for existence of cracks, deformations and signs of excessive wear, estimate a condition of gear wheels.

2. Check components of synchronizers for existence of cracks of signs of excessive wear, cracks and other mechanical defects. Estimate a condition of naves, the sliding couplings, the blocking rings, keys and other details of assemblies. 3. Measure gap size between the blocking ring of the synchronizer and a gear wheel (for the 4th and 5th transfers). The nominal rate lies within the range of 1.0 ÷ 1.35 mm with the admission on wear to 0.7 mm.

4. Estimate freedom of rotation of bearings. Check bearing assemblies for existence of cracks, cavities and other mechanical damages.

ASSEMBLY

PERFORMANCE ORDER

1. Collect the synchronizer of 1-2 transfers. Track correctness of introduction of components to gearing. 2. Establish the conducted gear wheel of the 1st transfer and the blocking ring of the synchronizer of the 1st transfer. Press a nave of the synchronizer of 1-2 transfers. Track correctness of orientation of components.

3. Put the sliding coupling of the synchronizer of 1-2 transfers and its blocking ring.

4. Selection of persistent rings of a nave of the synchronizer of 1-2 transfers achieve minimization of a gap of a groove (0 ÷ 0.1 mm). 5. Put the conducted gear wheel of the 2nd transfer on assembly of a shaft.

6. Put a gear wheel of the 3rd transfer, then the 4th and 5th.

7. Selection of a persistent ring achieve minimization of a gap in a groove of the conducted gear wheel of the 5th transfer (0 ÷ 0.15 mm).

8. Press a persistent washer and the back bearing of a secondary shaft.

9. Put the forward bearing.

Dismantle of assembly of the main transfer

DISMANTLING

PERFORMANCE ORDER

1. Turn out fixing bolts and remove the conducted koronchaty gear wheel of the main transfer. 2. Remove the speedometer drive.

3. Vypressuyte side bearings of differential, - you remember that the right and left bearings are not interchangeable and at installation have to be put strictly on the former places.

4. Release a fixing pin and take an axis of satellites. 5. Take satellites and side gear wheels from a differential box.

Check of a condition of components

PERFORMANCE ORDER

1. Check a condition of the interfaced surfaces of a box of differential, side a gear wheel and satellites.

2. Estimate degree of wear of washers. 3. Check freedom of rotation of bearings. Make sure of lack of signs of mechanical damages and cavities of pointed corrosion.

ASSEMBLY

PERFORMANCE ORDER

1. Establish washers on side gear wheels of differential. Fill side gear wheels and satellites on the regular places in a differential box.

2. Insert an axis of satellites.

3. By means of special adaptation and the dial measuring instrument of plunger type measure the size of a side play of landing of a side gear wheel in a differential box.

4. The result of measurement should not exceed sizes 0.1 ÷ 0.2 of mm, otherwise achieve the required result by selection of new washers.

5. Establish a pin.

6. Establish the conducted gear wheel of the main transfer.

7. Install the speedometer drive.

8. Napressuyte on differential side bearings.

Check of a condition of components of the mechanism of the choice of transfers

PERFORMANCE ORDER

Check the surfaces of sliding of components of the mechanism of the choice of transfers for existence of scratches, attritions and other mechanical damages.